395426 s20 s23 2006 - hydmech.com · 1 s-20/23 395426 january 2006 revision a thank you, on behalf...
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S-20/23395426
January 2006 Revision ATHANK YOU,
On behalf of everyone at HYD.MECH, I would like to thank and congratulate you on your decision to purchase a HYD.MECH band saw.
-ting costs while boosting quality and productivity.
To ensure you are maximizing the power and versatility of your new HYD.MECH band saw, please take the time to famil-iarize yourself and your employees with the correct operation and maintenance procedures as outlined in this manual.
Thank-you.
HYD.MECH GROUP LIMITEDP.O. BOX 1030, 1079 Parkinson RoadWoodstock, Ontario Canada, N4S 8A4Phone: (519) 539-6341Service 1-877-237-0914Sales 1-877-276-SAWS(7297)Fax (519) 539-5126e-mail: [email protected]
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TABLE OF CONTENTS
SECTION 0 - SAFETY INSTRUCTIONSSUMMARY .......................................................................................................................................0.1FOREWORD ....................................................................................................................................0.2BASIC RULES .................................................................................................................................0.4RESPONSIBILITIES OF THE OWNER ...........................................................................................0.5RESPONSIBILITIES OF THE OPERATOR AND MAINTENANCE PERSONNEL .........................0.6
SECTION 1 - INSTALLATIONSAFETY PRECAUTIONS ................................................................................................................1.1VISUAL INSPECTION .....................................................................................................................1.2LIFTING THE S20/23 WITH A FORK LIFT......................................................................................1.3WRAPPED FOR SHIPPING ............................................................................................................1.3LEVELLING THE SAW....................................................................................................................1.3HYDRAULIC OIL .............................................................................................................................1.3WIRING CONNECTIONS FOR S20/S23 .........................................................................................1.4CUTTING FLUID..............................................................................................................................1.4POWER CABLE ROUTING (S20/S23)............................................................................................1.4WIRING CONNECTIONS ................................................................................................................1.4WIRING CONNECTIONS FOR MACHINES WITH VFD OPTION...................................................1.5
SECTION 2 – OPERATING INSTRUCTIONSHYDRAULIC CONTROLS ...............................................................................................................2.1ELECTRICAL CONTROLS..............................................................................................................2.1ELECTRICAL CONTROLS (S20 VFD / S23 VFD OPTION) ...........................................................2.2ELECTRICAL CONTROLS (S20H VFD / S23H VFD OPTION) ......................................................2.3HYDRAULIC CONTROLS (S20H VFD / S23H VFD OPTION)........................................................2.3BLADE BASICS...............................................................................................................................2.4OPTIMUM BLADE PITCH ...............................................................................................................2.5VISE OPERATION ...........................................................................................................................2.5HEAD SWING AND BRAKE............................................................................................................2.6COOLANT CONTROLS...................................................................................................................2.6BLADE SPEED SELECTION (NOT APPLICABLE TO S-23) .........................................................2.6CHANGING BELT POSITION..........................................................................................................2.7GUIDE ARM POSITIONING ............................................................................................................2.7
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SECTION 3 - MAINTENANCE & TROUBLESHOOTINGBLADE CHANGING PROCEDURE.................................................................................................3.2BLADE GUIDE ADJUSTMENT .......................................................................................................3.3BLADE BRUSH ADJUSTMENT......................................................................................................3.4ANGLE BRAKE ADJUSTMENT......................................................................................................3.4BELT TENSION ADJUSTMENT (NOT APPLICABLE TO S23)......................................................3.4HEAD DOWN LIMIT SWITCH .........................................................................................................3.5LUBRICATION.................................................................................................................................3.5GEARBOX LUBRICATION S23 ......................................................................................................3.6GEARBOX LUBRICATION S20 WITH VFD OPTION .....................................................................3.6TROUBLE SHOOTING....................................................................................................................3.7
SECTION 4 - ELECTRICALS20 / S23 COMPONENT LAYOUT: VFD OPTION ..........................................................................4.1S22H / S23H COMPONENT LOCATION: VFD OPTION ...............................................................4.4FOR ELECTRICAL SCHEMATICS AND COMPONENT PARTS LIST SEE PDF ON ATTACHED CD. ...................................................................................................................................................4.7
SECTION 5 - HYDRAULICFOR HYDRAULIC SCHEMATICS AND PLUMBING DIAGRAMS SEE PDF ON ATTACHED CD. ...................................................................................................................................................5.1
SECTION 6 - MECHANICAL ASSEMBLIESFOR MECHANICAL ASSEMBLY DRAWINGS SEE PDF ON ATTACHED CD ..............................6.1
SECTION 7 - OPTIONSBLADE BREAKAGE SWITCH (STANDARD ON CE MACHINES) ................................................7.1MIST COOLANT SYSTEM ..............................................................................................................7.1HYDRAULIC POWER PACK (S20H / S23H): .................................................................................7.2VARIABLE VISE PRESSURE OPTION (S20H / S23H): .................................................................7.2OVERHEAD BUNDLING (HYDRAULIC S20H / S23H)...................................................................7.3WORK LAMP ASSEMBLY...............................................................................................................7.4MATERIAL STOP.............................................................................................................................7.4FOR OPTIONAL ASSEMBLY DRAWINGS SEE PDF ON ATTACHED CD. ...................................7.4
SECTION 8 - SPECIFICATIONSS20 CUTTING CAPACITY...............................................................................................................8.2S20 MACHINE LAYOUT (SHEET 1) ...............................................................................................8.3S20 MACHINE LAYOUT (SHEET 2) ...............................................................................................8.4S23 CUTTING CAPACITY...............................................................................................................8.6S23 MACHINE LAYOUT (SHEET 1) ...............................................................................................8.7S23 MACHINE LAYOUT (SHEET 2) ...............................................................................................8.8
SECTION 9 - WARRANTYWARRANTY.....................................................................................................................................9.1
0.1
SECTION 0 - SAFETY INSTRUCTIONSSUMMARY
All persons operating this machine must have read and understood all of the following sections of this Manual:Section 0 SAFETYSection 2 OPERATING INSTRUCTIONS
However, as a memory aid, the following is a summary of the Safety Section.
Put Safety First
Mandatory Information – What operators and maintenance people must have read and understood.
Signatures -mation.
Basic Rules – only use this machine when
it is in good working order
all safety equipment is in place and functional
operations are in compliance with this manual
Owner is responsible to
keep Manual accessible at the machine
ensure only reliable, fully trained personnel work with the machine
keep the machine in good working order
Operator and Maintenance Personnel are responsible to:
keep all safety equipment in order, check its function at the beginning of each shift, and report any shortcomings
shut-down machine and report any faults or malfunctions which could impair safety
understand and obey safety hazard labels
not to wear un-restrained long hair, loose clothing or jewellery
wear all required personal protective equipment
not to wear gloves within 24 inches of moving blade
maintain a clean working area and machine
always use Lock-out when performing maintenance or repairs.
0.2
FOREWORDPut Safety First!
This Safety Section contains important information to help you work safely with your machine and describes the dangers inherent in our machines. Some of these dangers are obvious, while others are less evident.
It really is important to PUT SAFETY FIRST. Make it a habit to consider the hazards associated with any action BEFORE
from your supervisor.
The SAFETY FIRST approach is particularly necessary when you do something new, or different, and most people in-stinctively recognize this, although impatience may still cause them to take unnecessary risks.
Danger also lurks in the routine task that we have done over and over. Here, familiarity, boredom, or tiredness may lull us into unthinking, automatic repetition. Be alert for this, and when you feel it happening, stop and take stock of your situa-tion. Review the safety hazards associated with what you are doing. That should get your brain working again.
you get hurt.
You owe it to yourself, your family, and your co-workers to PUT SAFETY FIRST.
Mandatory Information
All persons operating this machine must have read and understood all of the following sections of this Manual:
Section 0 SAFETY
Section 2 OPERATING INSTRUCTIONS
Personnel involved in installation and maintenance of the machine must have read and understood all sections of the manual
instruction.
0.3
Signatures
I have read and understood all parts of Section 0 – Safety, and Section 2 – Operating Instructions.
Name Date Signature
I have read and understood all parts of this Operation and Maintenance Manual.
Name Date Signature
0.4
BASIC RULESIntended Use
American National Standards Institute Standard B11.10 Safety Requirements for Metal Sawing Machines.However, all machines may endanger the safety of their users and/or third parties, and be damaged,
Exclusion of Misuse
Misuse includes, for example:
Sawing hazardous materials such as magnesium or lead
Operating the machine without all original safety equipment and guards
Liability
The machine may only be operated:
when it is in good working order, and
when the operator has read and understood the Safety and Operating Instructions Sections of the Manu-al, and
when all operations and procedures are in compliance with this Manual.
Hyd-Mech Group cannot accept any liability for personal injury or property damage due to operator errors or non-compliance with the Safety and Operating Instructions contained in this Manual.
0.5
Responsibilities of the owner
Organization of work
This Operation and Maintenance Manual must always be kept near the machine so that it is accessible to all concerned.
The general, statutory and other legal regulations on accident prevention and environmental protection must also be observed, in addition to the Manual material. The operators and maintenance personnel must be instructed accordingly. This obligation also includes the handling of dangerous substances and the provision and use of personal protective equipment.
Ensure that work on the machine is only carried out by reliable persons who have been appropriately trained for such work.
Training
Everyone working on or with the machine must be duly trained with regard to the correct use of the ma-chine, the correct use of safety equipment, the foreseeable dangers that may arise during operation of the machine, and the safety precautions to be taken.
In addition, the personnel must be instructed to check all safety devices at regular intervals.
Persons being trained on the machine may only work on or with the machine under the constant supervi-sion of an experienced operator. Observe the minimum age limits required by law.
Condition of Machine and Workplace
Ensure that the machine and its safety equipment is kept in good working order.
Ensure that the work area is well lit, and protected from the elements, such as rain, snow, abrasive dust, and extremes of temperature.
of work pieces.
0.6
Responsibilities of the operator and maintenance personnel
Safety equipment
All machines are delivered with safety equipment that must not be removed or bypassed during operation.
The correct functioning of safety equipment on the machine must be checked:
at the start of every shift.
after maintenance and repair work
Emergency Stop Button ( E-Stops)
Always be aware of the location of the Emergency Stop Button(s). Do not allow material or objects to block your access to an Emergency Stop.
Damage
If any changes capable of impairing safety are observed in the machine or its operation, such as damage, malfunctions, or irregularities, then appropriate steps must be taken immediately, the machine switched off, locked-out, and the fault reported to the responsible person.
Safe operation
The machine may only be operated when in good working order and when all protective equipment is in place and operational.
Keep a safe distance from all moving parts – especially the blade and vises
Stock should not be loaded onto the saw if the blade is running
Long and heavy stock should always be properly supported in front of and behind the saw.
Faults
The machine must be switched off and locked-out before starting to remedy any faults.
Safety hazard labels
Safety hazard labels, and other instructional labels on the machine must be observed. They must be clearly visible and legible at all times. If they become damaged they must be replaced.
Clothing, jewellery, protective equipment
Personnel operating or working on the machine must not wear un-restrained long hair, loose-
-tective equipment such as safety glasses and safety boots and any other equipment required by plant regulations.
0.7
Gloves
Experience has shown that careless use of gloves around machinery is a major factor in serious hand injuries.
Gloves should not be worn when operating or adjusting the machine, except:
Wear protective gloves when handling bandsaw blades at blade changes.
Gloves may be worn when handling work pieces, only if the machine is in Manual Mode and the bandsaw blade is not running.
If the machine is running in Auto Mode, and only if the cut parts are greater than 24 inches long, it may be possible to safely wear gloves for handling the cut parts, but the wearer of the gloves must never put his hands near the blade for any reason. If the cut
parts bucket or other suitable arrangement to avoid the necessity to pick them off the machine by hand.
Hearing protection
Ear protection must be worn whenever necessary.
The level and duration of noise emission requiring hearing protection depends upon the national regulations in the country in which the machine is being used.
The actual level of noise emission by band sawing machines depends upon work piece size, shape and material, blade type, blade speed and feed rate.
The only practical course of action is to measure the actual noise emission levels for the type of work that is typically done. With reference to national standards, decide upon the necessary hearing protection required.
In the absence of such measurements, it is advisable for anyone exposed to long periods of moderate to loud noise to wear hearing protection. It is important to understand that hearing loss is gradual and easily goes un-noticed until it is serious and irreversible.
Workplace
must be level and clean, without any build-up of chips, off-cuts, coolant, or hydraulic oil.
The workplace must be well lit, and protected from the elements, such as rain, snow, abrasive dust, and extremes of temperature
Nothing may ever be placed on, or leaned against the machine, with the obvious exception of the work piece on the table and conveyor of the machine.
0.8
Master Disconnect
off the master electrical disconnect switch, and locking it out so that it cannot be switched on again without authorization.
On Hyd-Mech machines the Master Disconnect Switch will be of one of three types:
Rotary switch mounted in electrical control cabinet door and inter-locked with door
Lever switch mounted in separate box mounted on the machine
Supply disconnect switch supplied by user at installation and usually wall-mounted within sight of the machine, depending upon local regulations.
In almost all jurisdictions, it is required that owners of industrial equipment establish and post lock-out pro-cedures. Know and use the lock-out procedures of your company or organization.
Residual Risks
The machine is still not completely de-energized if an electrical cabinet door type switch is locked-out.
The line side of the disconnect switch itself remains energized.
Variable speed blade drives store dangerous voltage in their capacitors, and this requires time to dissipate. After locking out power, wait 3 minutes before beginning to work on machine electrical circuits.
If compressed air is supplied to the machine to power a mist lubrication system or other devices, it should be disconnected, and any stored air pressure released before working on the machine.
The weight of individual machine components represents stored potential energy that can be released if they fall when disconnected. Secure these components with adequate hoisting gear before disassembly.
1.1
SECTION 1 - INSTALLATIONUpon delivery of your new S-20/23 saw, it is imperative that a thorough inspection be undertaken to check for any damage that could have been sustained during shipping. Special attention should be paid to the electrical and hydraulic systems
SAFETY PRECAUTIONS
The S-20/23 has been designed to give years of reliable service. It is essential that operators be alerted to the safe opera-tion of this saw, and the practices to avoid that could lead to injury. The following safety rules are at the minimum neces-sary for the safe installation, operation, and maintenance of the saw. Take every precaution for the protection of operators and maintenance personnel.
POWER HOOK-UPS AND REPAIRS SHOULD BE ATTEMPTED ONLY BY QUALIFIED TRADESMEN.
THE SAW SHOULD BE LOCATED IN AN AREA WITH SUFFICIENT ROOM TO SAFELY LOAD STOCK INTO THE SAW. SECURE THE SAW TO THE FLOOR.
THE AREA AROUND THE SAW SHOULD BE MAINTAINED IN A CLEAN AND TIDY CONDITION TO AVOID OBSTACLES OPERATORS COULD TRIP OVER.
THE S-20/23 SHOULD ONLY BE OPERATED ACCORDING TO THE SPECIFICATIONS OF THE SAW. AVOID UNSAFE USAGE PRACTICES.
IF AT ANY TIME THE SAW DOES NOT APPEAR TO BE OPERATING PROPERLY IT SHOULD BE STOPPED IMMEDIATELY AND REPAIRED.
OPERATOR:
THE SAW SHOULD NEVER BE OPERATED UNLESS ALL GUARDS AND DOORS ARE IN PLACE AND CLOSED.
KEEP A SAFE DISTANCE FROM ALL MOVING PARTS - ESPECIALLY THE BLADE AND VISES.
LOOSE CLOTHING AND GLOVES SHOULD NEVER BE WORN WHILE OPERATING THE SAW. COVER LONG HAIR.
STOCK SHOULD NOT BE LOADED ONTO THE SAW IF THE BLADE IS RUNNING.
LONG AND HEAVY STOCK SHOULD ALWAYS BE PROPERLY SUPPORTED IN FRONT OF AND BEHIND THE SAW.
NEVER ATTEMPT TO DISLODGE OR MOVE STOCK WHILE THE BLADE IS MOVING. TAKE THE TIME TO STOP THE SAW BLADE, REMOVE OBSTRUCTIONS, AND RESTART BLADE.
MUST WEAR EYE PROTECTION
MAINTAIN PROPER ADJUSTMENT OF BLADE TENSION, BLADE GUIDES, AND THRUST BEARINGS
HOLD WORK PIECE FIRMLY AGAINST TABLE
DO NOT REMOVE JAMMED CUTOFF PIECES UNTIL BLADE HAS STOPPED
NO MODIFICATIONS TO THE MACHINE ARE PERMITTED WITHOUT PRIOR APPROVAL FROM HYD-MECH. ANY AP-PROVED MODIFICATIONS SHOULD ONLY BE UNDERTAKEN BY TRAINED PERSONNEL.
1.2
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2
3
1. Head - keep away from moving blade2. Vise - never load stock with the blade moving3. Head - watch for head descending to the table4. Pivot - check for head movement blockage5. Drive - secure pulley cover when running
VISUAL INSPECTION
4
5
1.3
LIFTING THE S20/23 WITH A FORK LIFT
The S-20/23 is shipped with a shipping pallet attached to the saw. When lifting the pallet with a
-anced. The pallet length dimension is 84” (2132mm). Minimum fork length of 72” (1827 mm) is recommended to safely lift the pallet.
WRAPPED FOR SHIPPING
The S-20/23 is shrink-wrapped for shipping from our plant. Remove the wrapping from around the saw. Complete the inspection for signs of damage. Undo the bolts that hold the saw to the pallet. Retain these bolts to use for leveling.
-ing plates located at the corners of the saw. The larger diameter hole is used for retaining during shipping and for use with
LEVELLING THE SAW
-
give a small incline towards this area helps to ensure the coolant supply returns to the container.
HYDRAULIC OIL
The S-20/23 is supplied with ISO VG22 hydraulic oil. Substitutes must be of the same vis-cosity in order for the system to work properly.
the cylinder only with the head in the down position. The head cylinder is a self air-bleeding cylinder with a small port in the top plate. If excess oil is displaced from this port, the cylinder is working normally.
1.4
CUTTING FLUID
The S-20/23
- Oil based; dilute 1:10 ratio (one part concentrated coolant to 10 parts water)- Synthetic; dilute as recommended by manufacturer.
POWER CABLE ROUTING (S20/S23)
The main power cable can be routed up through the bottom of the head frame to the access hole in the end of the control panel. Cable liquid tight reliefs should be used to secure the cable into the control panel to ensure there is no movement of the cable when the machine is operated.
WIRING CONNECTIONS
After the machine is leveled and anchored the necessary power hook-up needs to be performed.
In order to provide a safe operation as well as to prevent potential damage to the
As supplied your new S-20/23 is set to run on three phase voltage or single phase. The supply voltage of the machine displayed on the Serial # Plate and the voltage label.
Connection from the main power supply is made to the L1, L2, L3 (L1 and L2 for single phase) and ground terminals be-tween the contactor and the transformer.
Supply conductor should be rated for the current supplied and should be protected by time delay fusing rated for the am-perage stated on the machine serial plate.
Check for •Signs of damage to the electrical cables from shipping or installation. •Correct phase order. The blade should be running in the counter clockwise direction. If the blade direc-
tion is wrong, two lines should be reversed.
ContactorL1, L2, L3 and Ground
L1 L2 and Ground for Single Phase Voltages
Contactor
Wiring connections for S20/S23
1.5
Wiring Connections for machines with VFD option
The power cable should be routed through the hole found at the bottom right of the box. A suitable strain relief should be used.
L1, L2, L3, and ground terminals found inside of the box
2.1
SECTION 2 – OPERATING INSTRUCTIONSThe operator control panel provides the operator with all the controls necessary to operate the saw after the cutting angle has been set and the stock has been loaded and secured. All of the electrical functions and the Feed Rate setting are operated from the control panel.
HYDRAULIC CONTROLS
FEED RATE KNOB - Controls feed rate of the head. This rate can be set on the scale of 1to 10. As the number increases so does the feed rate.
HEAD CONTROL LEVERHOLD - Stops and holds the Head at the current
position.FEED - The Head will descend at the rate set by
the Feed Rate knob. DOWN - Allows for rapid approach of the blade to
the workpiece.
ELECTRICAL CONTROLS
FUSE- Check if power fails. Twist & pull to remove the fuse.
COOLANT Switch -
START Button - This button starts the saw blade. The blade will not start with the Head in the down position or if any safety interlock switches (if equipped) are not closed.
STOP Button - Pressing the RED mushroom button will STOP the blade.
2.2
ELECTRICAL CONTROLS (S20 VFD / S23 VFD OPTION)
Blade Speed (1BS) – m/min). Adjustment should be made only when the blade is running.
Coolant Switch (1SS) – ON:OFF:
AUTO: Blade running.
Blade Start (5PB) – A green push button. The blade will not start with the head in the down position, if any safety switch-es are not closed, or if the emergency stop is depressed.
Emergency Stop (1PB) – This red mushroom head push button will stop the blade.
NOTE: Hydraulic controls are the same as the S20/S23 machine.
2.3
ELECTRICAL CONTROLS (S20H VFD / S23H VFD OPTION)
Coolant Switch (1SS) – ON:OFF:
AUTO: Blade running.
Blade Speed (1BS) – m/min). Adjustment should be made only when the blade is running.
Blade Start (5PB) – A green push button. The blade will not start with the head in the down position, if any safety switch-es are not closed, or if the emergency stop is depressed.
Blade Stop (4PB) – This black push button will stop the blade motor.
Hydraulic Start (2PB) - This green push button will start the hydraulic system. It will illuminate when pressed and held momentarily. The hydraulics will not start if the emergency stop is depressed.
Emergency Stop (1PB) – This red mushroom head push button will stop the blade and hydraulic motors. The vise will hold its position, but pressure will begin to drop off. Long pieces of material should always be supported so they will not fall while the machine is shut down.
HYDRAULIC CONTROLS (S20H VFD / S23H VFD OPTION)
VISE CONTROLS
OPEN The vise will open when the lever is pushed up.
HOLD The vise will hold its position when the lever is in the center position.
CLOSE The vise will close when the lever is pushed down.
NOTE: See Section 7 if the bundling option is present.
HEAD CONTROLS
UP The head will rise as long as the lever is pushed up.
HOLD The head will stay at its current position when the lever is in this position.
DOWN The head will descend at the set Feed Rate.
FEED RATE DIAL The speed at which the head will descend can be set on the scale of 1 to 10. As the number increases so does the feed rate.
2.4
BLADE BASICS
Technology is rapidly changing all aspects of production machining. Metal cutoff is no exception. The advances
price of high-technology blades. Variable pitch, bi-metal blades (like the 4/6 or ¾ bi-metal blade supplied with the machine) last much longer, cut faster and more accurately than conventional carbon steel blades. In order
extremelyslow feed rate. It is also advisable to utilize a slow blade speed.
life.
piece at the standard recommended blade speed for that material, but with a feed rate reduced to about
blade approaches the end of the second cut. Keep increasing feed rate in this fashion so that normal feed rate is reached after 100-120 sq inches of cutting.
B. Generous coolant application is essential with almost all materials. A high quality and well mixed cool--
prevent the blade from being scored by the carbide guides.C. The stock being cut must be securely clamped in the vises. Stock movement during cutting will strip
blade teeth. Noticeable stock vibration reduces performance and blade life. Consideration should be given to reorient the stock or additional clamping measures (wood between vise jaws and work-piece)
D. The proper blade speed for the work-piece material must be selected. Use the following chart as a starting point.
a. Blade speeds higher than recommended will quickly dull the blade. Blue chips are evidence of excessive blade speed.
b. Lower than recommended speeds will not prolong blade life and will require reduced feed rate, but, reduced speeds may be helpful in reducing vibration and would increase blade life in that case.
E. The proper feed rate must be applied. Feed rate is the speed at which the head free falls and is set with the feed rate control knob. The head will descend more slowly when the blade encounters the work-piece but the force of the blade on the work will not be changed unless the setting
is provided by the appearance of the cut chips which ideally form nicely curled clock springs (note that cast irons and interrupted cuts result in short, broken chips even at ideal feed rates).Excessive feed rate will result in short blade life and/or crooked cuts.
140, 220140, 22090, 140140, 22090, 140140, 220140, 220140, 220
310
220
(in SFM)
2.5
OPTIMUM BLADE PITCH
Teeth per inch (T.P.I.)
Selecting a blade with a proper tooth pitch is important in order to achieve optimal cutting rates and good blade life.
many teeth per inch is recommended. For wide materials a blade with a coarse pitch should be used.
It is impractical to change the blade to the proper pitch every time a dif-ferent width of material is cut and it is not necessary. However, remem-
must be fed slower on wide material because the small gullets be-tween the teeth will become packed with chips before they get across and out of the cut. Too coarse a blade must be fed slower because it has fewer teeth cutting and there is a limit to the depth of a cut taken by each tooth.
MECHANICAL CONTROLS
VISE OPERATION
The material clamping vise is a cam operated double handle locking vise. The saw operator can push the vise handle to close the jaw on the material and then lock it from either side of the saw. The handles have two posi-tions, forward toward the stock to unlock the vise and away from the stock to lock.
Vise Handles
2.6
HEAD SWING AND BRAKE
An integral function of the S-20/23 Series II is the ability to make mitered cuts at angles between 90 and 45 . The Head swing of the S-20/23 Series II is easily changed to set
lever, and then manually moving the Head to the cutting angle desired. An angle scale with a pointer in clear view of the saw operator allows for accurate setting of the cutting angle.
The Angle Brake lever is then locked in position by pushing it into the down position. Note that the angle brake should be locked into position whenever cutting with the saw. To set the saw to the 90 position, set the Head in the fully down position and move the Head until the frame meets the 90stop bolt which is located on the vise post.
COOLANT CONTROLS
The main coolant control is found on the control panel.
The S-20/23 Series II band saw is equipped with two independently controlled coolant spouts that are capable of supplying a generous
blade as it moves through the carbide pads into the material to be cut. The guide arm outlets should be adjusted to apply an even covering of coolant to the blade.
hose should be used when cutting solid bars, bundles, or wide
material where the blade is cutting.NOTE: When cutting materials that do not need constant coolant,
to prevent blade scoring by the carbide pads as the blade moves through them.
about mid span of the cut.
BLADE SPEED SELECTION (not applicable to S-23)
The blade speed of the S-20 can be changed between four different speeds. The speed is determined by the ratio of the pulleys that drive the V belt. The four pulley sets give the optional speeds of 90, 140, 220 and 310 ft/min.
Note: Blade drive with single phase motors have only three speeds available.
2.7
CHANGING BELT POSITION
To change the blade speed of the S-20 it is necessary to release the V belt tension and move the belt to another set of pulley grooves. The tension on the V belt is maintained by means of a toggle handle assembly that moves the motor. As the handle is moved to is locking position the motor is driven tight against the V belt. The toggle handle can be adjusted to change the effective tension on the V belt by setting the lock nuts which mount the handle to the motor mount plate. The motor mount plate pivots on rubber bushings that support the motor.
GUIDE ARM POSITIONING
The S-20/23 Series II guide arms are adjustable to accommodate varying material widths. The guide arms should be adjusted as close to the material width as possible while still allowing the material to pass between them. This process of matching the guide arm width to the material size is important to optimize blade life.
To adjust the guide arms the locking handles are loosened and then the guide arms will slide on the main guide bar that holds them. To loosen the handle it should be turned counter clockwise and to tighten the handle, turn it clockwise. The photo illustrates the Guide Arms with the handles in the LOCKED position.
Carbide Levers in Tensioned Position (Upright)
3.1
LOCK -OUT
Purpose:To prevent injury to workers caused by unexpected start-up of machines being worked on.ORWhere the starting of a machine or device may endanger the safety of a worker.
a) Control switches or other control mechanisms shall be locked out; ANDb) Other effective precautions necessary to prevent such starting shall be taken.
LOCK OUT PROCEDURE
Whenever work is to be performed on a machine, the following steps shall be taken:
1. Operator shuts down the machine
2. The person in charge should follow Lockout procedures as is required by his organization.
Switch off before beginning work.
The emergency switch, which is used to turn the hydraulics off, should not be the only means of shutting the power off before cleaning or performing maintenance to the machine. The main power disconnect should be switched off and locked.
When performing maintenance on the electrical system the main disconnect, which supplies power from the electrical service to the machine, should be switched off.
Allow three minutes after turning off the power from the main electrical service to the saw before opening any electrical enclosures. Your machine might be equipped with a variable frequency
to completely discharge
SECTION 3 - MAINTENANCE & TROUBLESHOOTING
3.2
BLADE CHANGING PROCEDURE
NOTE: Wear gloves for protection from the sharp blade.
1. Open the idler wheel and drive wheel doors and swing the head to 45 as this will make it easier to grip the blade closer to both wheels
2. Loosen the Blade Tensioner by turning counter clockwise.3. Loosen the carbide tension handles by turning counter clockwise ¼
turn.4. At the top of the head, the saw blade runs in a protective channel.
Grip the blade at each end of this channel and twist the blade teeth down past the channel and slide the blade forward. Let the blade rest on the out-feed table, and then slide the blade down and out of the carbide guides.
5. Your new blade will be in a coil. While wearing gloves, hold the blade away from yourself, and twist the blade to uncoil it. Do not let the
damage.6. Place the new blade in the carbide guides and then slide the blade
over the wheels. The teeth should be pointing towards the drive side as they pass through the carbide guides.
7. With the blade in place, turn the tensioner handle clockwise until the large black washer contacts the stop bolt. This will set the blade tension correctly.
8. With the blade tension set, turn the two carbide-locking handles clockwise to the locked position. Jog the blade a few rotations to check that the blade is not moving in or out on the blade wheels. NOTE: As the blade tracking will stay fairly constant, it should be checked occasionally as shown on the drive wheel-tracking photo below. The blade teeth should protrude from .185” to .200” from the face of the blade wheels. If the tracking requires adjustment, follow the instruction below.
9. BLADE TRACKING ADJUSTMENT – First, inspect the blade wheels for wear or damage and repair as required. Blade tracking adjustment
below, adjust the worst wheel, jog the blade and recheck both wheels. Repeat this process until both wheels
a. IDLER WHEEL ADJUSTMENT S-20 Line On the blade tensioner slide assembly, there are three 9/16” hex head bolts. Loosen the two bolts at the left end by ¼ turn. Loosen the single bolt at the right side of the slide assembly by ½ turn. In the two holes above and below this bolt are two 3/16” Allen key set screws. Turn both set screws ¼ turn and tighten the hex bolt at the right, and then the two bolts at the left. Turning the setscrews clockwise will pull the blade onto the wheel, and turning counter clockwise will push the blade off the wheel. Each ¼ turn will move the blade approximately .02” (5.1mm). There is also a single setscrew at the left end of the slider. Turning it clockwise will push the blade off the wheel.
b. IDLER WHEEL ADJUSTMENT S-23 Line
adjustments, bolts A & B should be loosened but remain snug. This will allow easy movement for the slide assembly. It should be noted that most adjustments can be made with the B & D bolts. Loosening bolt A and turning in set screws C by equal amounts will move the blade off the wheel. Loosening bolt B and turning in set screws D by equal amounts will move the blade on to the wheel. After each C or D adjustment, tighten bolts A & B, run the blade and then check the tracking.
c. DRIVE WHEEL ADJUSTMENT – On the wall behind the drive wheel are two adjusting bolt assemblies and two hex bolts. Loosen all four of them with a ¾” socket and turn the larger hex head bolts ¼ turn with a 1 1/8” socket and extension and then tighten the two bolts in the assemblies. Then tighten the two hex bolts at the left. Turning the 11/8” bolts clockwise will pull the blade onto the wheel and turning counter clockwise will push the blade off. Each ¼ turn will move the blade approximately .02”.
10. Check the blade brush adjustment (p. 3.4) to be sure the blade is being cleaned properly.
Blade Tensioner
3.3
BLADE GUIDE ADJUSTMENT
At the bottom of the guide arms are the carbide blade guide assemblies, the photo shows the carbide-locking handle. These assemblies will need to be adjusted occasionally as the carbide pads become worn. To adjust properly, follow this simple procedure. Loosen the hex nut on the locking handle with a 9/16 wrench and turn the handle clockwise until it rests against the coolant tap on the idler guide arm or the roll pin on the drive guide arm. Turn the setscrew clockwise with a 3/16 Allen key until tight and then loosen 1/8 turn and tighten the hex nut. This should put just enough pressure on the blade to permit you to push the blade down approximately 1/8”.
CC A BD D
S-23 BLADE TENSION ASSEMBLY
S-20 BLADE TENSION ASSEMBLY
3.4
BLADE BRUSH ADJUSTMENT
The machine leaves the factory with the blade brush adjusted for maximum life of the brush. This setting places the ends of the blade brush wires so as to contact the blade at the bottom of the blade gullets. The plastic drive wheel that is driven by the drive wheel face should be held against the blade face with the minimum force that is necessary. As the blade brush wears it is necessary to periodically adjust it closer to the blade or if a new brush is installed, further away from the blade.
As shown, there are two springs on socket head screws holding the brush assembly against the blade. There is also an adjusting socket set screw with a hex nut on it. Loosen the hex nut with a 9/16” wrench and turn the setscrew counter clockwise with a 3/16” Allen key. This will move the brush closer to the blade. Adjust the setscrew so that the brush cleans to the bottom of the blade gullets and tighten the hex nut.
ANGLE BRAKE ADJUSTMENT
The clamping force on the swivel brake can be adjusted to ensure that the Head is held securely and does not move
head securely.
ANGLE BRAKE ADJUSTMENT PROCEDURE:
Step 5 – Swing the head to 45 and back to ensure that the head moves freely and does not bind on the pivot surfaces. Continue to step 6 if necessary.
BELT TENSION ADJUSTMENT (Not applicable to S23)
Drive belt tension is maintained by the locking of a toggle clamp assembly. The release of the toggle clamp permits the drive belt to be loosened so that the blade speed can be changed by selecting a different pulley ratio.
1. Stop the blade motor. Undo the cover latch and swing the pulley cover away.
2. At the midpoint between pulleys, you should be able to push the belt in ½”. Too much or too little movement will cause slippage or abnormal wear on the belt and other drive system parts.
3. If adjustment is needed, loosen the lock nut with a 9/16” wrench and turn the adjusting bolt until the belt tension is set.
4. Tighten the lock nut. Test the belt on all speeds, and then close the cover.
A
B
C
3.5
HEAD DOWN LIMIT SWITCH
The head down limit switch operates to cut power to the blade motor and the coolant pump motor when the Head has descended to the bottom of its travel in the Manual mode. The Head is adjusted so that the blade will descend slightly past the level of the vise wear strips. This setting is critical to ensure that the blade has cut fully through the stock.
The Head Down Limit switch is made with the Head fully down and when the spring post contacts the limit switch at the top of its travel. The Head Down Limit switch is located on the head frame near the pivot point as shown in the photo.
Adjustment of the limit switch is made by changing the position of the set bolt, which is located on the end of the spring post. Lengthening the set bolt will cause the limit switch to activate sooner as the spring post meets the limit switch roller. Shortening the setting bolt by turning it into the spring post will lengthen the time before the Head Limit Switch is activated.
LUBRICATION
The S20/23 was designed to minimize the maintenance requirements, however moving assemblies and contact faces need lubrication on a regular schedule. The lubrication requirements are primarily the saw pivot points which are equipped
General purpose grease is suitable for lubrication.
The lubricant should be applied as frequently as required. Main lubrication points are indicated on the following pictures.
Monthly lubrication is recommended.
Head Pivot
Pivot Pin and Angle Brake
Spring Post and Cylinder Eye
Infeed Rollers
3.6
GEARBOX LUBRICATION S20 with VFD Option
S320 synthetic oil. This oil has an ISO Viscosity Grade of 320 that is optimum for ambient temperatures from 20-70 Deg C (70-140 Deg F). The W86 was designed to be a sealed unit, so no oil change should be
the approved Shell type be used, this be equivelent viscosity wise and of the synthetic type. The lubricant must also have the necessary EP and anti-foaming additives.
GEARBOX LUBRICATION S23
synthetic oil. This oil has an ISO Viscosity Grade of 320 that is optimum for ambient temperatures from 20-70
used, this be equivelent viscosity wise and of the synthetic type. The lubricant must also have the necessary EP and anti-foaming additives.Subsequent oil changes should be made every 600 to 12000 hours of operation depending on load conditions. The intervals, however, should not exceed 4 years.
3.7
# PROBLEM PROBLEM CAUSE
1 Cutting out of square vertically.
Carbide guide adjustment incorrect (adjust).Feed rate excessive (reduce).Blade worn (replace).Guide arms too far apart.Blade pitch incorrect .
2 Cutting out of square horizontally.
Angle not set correctly (adjust).Stock not square in vise. (reset material)Angle pointer out of adjustment.Stock is not secure in the vise. (reset vise)
3
Head cylinder creeps:
In HoldCylinder cup seal defective (replace).3 position valve defective (replace).Hydraulic hose leaking.
In Feed Position Loosen jam nut and readjust pointer with feed rate at zero.
4 Blade tracking incorrect.Improper tension (adjust).Tracking needs adjustment.Wheel is worn or in poor condition.
5 Blade stalls in cut.
More tension needed.Excessive feed rate (reduce).Blade pitch incorrect.Carbide guides overtightened.
6 Blade vibrating excessively.
Blade speed too fast.More Blade tension needed.Guide arms too far apart.Feed rate too slow (increase).Carbide guides worn or loose (adjust or replace).
7 Excessive blade breakageExcessive blade tension (reduce).Excessive feed rate (reduce).Top guide(s) damaged (replace).
8
No coolant (add).Check coolant ports for blockage.Line blockage (blow out lines with compressed air).Coolant pump inoperable (replace).Coolant pump has lost its prime, Loosen screws, sink pump in coolant.
9 Blade will not start.
Lift head off limit switch.Control fuse blown.Push reset button.If present, Check safety door interlock switches.
10 Machine stops before cut is completed or runs on after cut is completed. Adjust head down limit switch bolt.
TROUBLE SHOOTING
4.1
The electrical schematics show some components labeled as TB1 to TB2 and these components are physically mounted on din rails. The illustration below shows the location of the Din rails with the installed components and the designated TB number.
The following pages will show and explain in brief how to understand the correlation between the electrical schematic and the control panel with regards to TB1 and TB2.
TB1TB1
VFDVFD
1TR1TR
SECTION 4 - ELECTRICAL
S20 / S23 Component Layout: VFD OPTION
4.2
TB1
A close up view of TB1 is shown. It is located in the main panel (MP).
For example, if the electrical schematic shows a terminal, described as TB1 1
This indicates that the terminal is located on din rail TB1 and is terminal #1.
TB15 This would indicate that the terminal is mounted on TB1 and is terminal #5.
TB11
TB11
1
CR6
23
1
CR6
23
TB1 5TB1 5
L1L2L356
L1L2L356
MS2MMS2M
4.3
TB2
TB2 is located in the HMI panel (Human Machine Interface). This houses the selector switches and push buttons.
As in the main panel the same concept applies, for example: TB2 3
This indicates that the terminal is located on din rail TB2 and is terminal #3.
TB2 3TB2 3
TB2TB2
33 6644 552211
4.4
S22H / S23H Component Location: VFD Option
The electrical schematics show some components labeled as TB1 and TB2 and these components are physically mount-ed on din rails. The illustration below shows the location of the Din rails with the installed components and the designated TB number.
The following pages will show and explain in brief how to understand the correlation between the electrical schematic and the control panel with regards to TB1 and TB2.
TB1TB1
VFDVFD
1TR1TR
4.5
TB1
A close up view of TB1 is shown. It is located in the main panel (MP).
For example, if the electrical schematic shows a terminal, described as TB1 1
This indicates that the terminal is located on din rail TB1 and is terminal #1.
TB13 This would indicate that the terminal is mounted on TB1 and is terminal #3.
TB1 3TB1 3
TB11
TB11
11
4.6
TB2
TB2 is located in the HMI panel (Human Machine Interface). This houses the selector switches and push buttons.
As in the main panel the same concept applies, for example: TB2 4
This indicates that the terminal is located on din rail TB2 and is terminal #4.
TB2 4TB2 4
TB2TB2
4.7
DT (Device Tag)
The remainder of the components in the control panel are labeled and are referred to in the documentation under the DT heading. For example:
DT, CR6 is the Coolant relay labeled CR6.
DT, LS2 is the limit switch for Head Down function labeled LS2.
DT, MS 2M is the contactor labeled MS 2M.
DT, SS1 is the selector switch for Coolant Control, labeled SS1
Page and Row Numbers
In each title block of the project (electrical documentation) there are 2 headers, which are:
1. Page. This refers to the current page number
2. Pg. This refers to the total number of pages in the entire project and is for internal HYD·MECH use only.
On each Page there are a row of 4 digit numbers on the left of the page. For example, Page 15 shows the numbers from 1500 to 1539.
The latter 2 digits refer to the row number, which in this case are from 00 to 39.
Whenever the electrical schematic shows a target to another page then the method described above should be used to locate the component, device, wire etc.
The same format applies when reading the wire list or cable list as the page and row number are included on the list.
The concept of the TB1 & TB2 arrangement also applies to the S23H machine.
FOR ELECTRICAL SCHEMATICS AND COMPONENT PARTS LIST SEE PDF ON ATTACHED CD.
7.1
SECTION 7 - OPTIONS
Note: A new blade may require initial lubrication with a small quantity of mist coolant applied directly to the blade at the idler guide arm to prevent blade squealing.
Mist coolant - the air powered pump delivers a regulatednumber of pulses of lubricant to a single applicator nozzle.The unit has two control screws.Pulse/Minute - adjusts rate of lubricant use. About 8 to 12 pulse per minute is optimum - more is not better.Air Screw - regulates the jet of air that projects the lubricant from the nozzle onto the blade. Adjustment should be such that lubricant covers the blade without blowing the mist beyond the back edge of the blade.
PULSE / MINUTE
AIR SCREW
MIST COOLANT SYSTEM
Blade breakage switch shuts down blade drive and hydraulic pump motor (S22H, S23H option) in case blade band tension is lost or the blade snaps. It will disable machine operation until the new blade is installed and tensioned.Note: Blade breakage will not disengage head feed operation.
LIMIT SWITCH 372523
BLADE TENSION ASSEMBLY
BLADE BREAKAGE SWITCH (Standard on CE machines)
7.2
HYDRAULIC POWER PACK (S20H / S23H):
System operates head up and vise.Power pack is mounted on the door at the drive side of the infeed table. Parts consist of .25Hp (.19 kW) electric motor, relief valve assembly, gear pump and tank assemblyThis option requires special heads and vise cylinder.
-mended replacement oils:
Texaco Rando HD46CHEVRON ECO Hydraulic oil AW ISO 46MOBIL DTE 25ESSO NUTO H46SHELL TELUS OIL 46
2. HYDRAULIC OIL LEVEL - Semitransparent plastic reservoir allows for easy oil level visual inspection. Oil level should be maintained so the reservoir is always 75-90% full. The useable volume of oil reservoir is 1 US Gallons (3.8 L).3. HYDRAULIC OIL CHANGE - It is recommended to change oil after every 1500 hours of operation or once a year.4. OIL TEMPERATURE - Oil temperature during steady operation should stabilize at about 55-60F (30-33 C) above room teperature. Thus in a 70F (21 C) shop one might expect an oil temperature of about 130F (54 C). Oil temperature should never exceed 176F (80 C).5. HYDRAULIC PRESSURE - Hydraulic pressure is factory set at 450-500PSI (3100-3450 kPa) and should not require any further atteneion.
VARIABLE VISE PRESSURE OPTION (S20H / S23H):
Vise clamping adjustment is located on the face of the hy-draulic power pack door. Clamping pressure is indicated by the pressure gauge adjacent to the pressure control knob. Turning the knob clockwise increases clamping
-nitely from 50PSI to 600PSI, full pump pressure. It has to be taken under consideration that clamp pressure set-ting will affect the clamp speed. The actual usable low clamp pressure setting may be higher than achievable by controls and is limited by mechanical friction of the vise assemblies.Vise clamping pressure components can be accessed easily for service by opening the power pack door.
7.3
OVERHEAD BUNDLING (HYDRAULIC S20H / S23H)
1. The relative speed of the bundling jaws and vise can be adjusted with the needle valves at each cylinder
a) The material should be loaded into the machine vises and advanced to a position where a trim can be performed.b) Close the Fixed Vise until the Overhead Bundling Arm is slightly (1/32” to 1/64”) above the material to be cut.c) Close the ball valve located on the Fixed Overhead Bundling cylinder to lock the position of the Overhead Bundling Arm and then operate as normal
control valve
control valve
7.4
WORK LAMP ASSEMBLY
WORK LAMP 371790
MATERIAL STOP
WORK STOP ASSEMBLYS22-G15-00A
FOR OPTIONAL ASSEMBLY DRAWINGS SEE PDF ON ATTACHED CD.
8.1
SECTION 8 - SPECIFICATIONS
CAPACITY:
90° Rectangle: 13” x 18” 90° Rectangle: 330 mm x 457 mm
90° Round: 13” diameter 90° Round: 330 mm
45° Rectangle: 13” x 10.75” 45° Rectangle: 305 mm x 273 mm
45° Round: 12” diameter 45° Round: 305 mm diameter
60° Rectangle: 13” x 7.25” 60° Rectangle: 330 mm x184 mm
60° Round: 8.5” diameter 60° Round: 216 mm diameter
BLADE:Length: 4115 mm
Width: 1” Width: 27 mm
Thickness: .035” Thickness: 0.8 mm
BLADE SPEED:90, 140, 220, or 320 SFM 27, 43, 67, or 98 m/min
75-350 SFM (Optional VFD) 22-107 m/min (Optional VFD)
BLADE GUIDES: Carbide Carbide
BLADE WHEEL DIAMETER: 16” 406 mm
DRIVE: Blade drive: 2 hp (3 hp Optional VFD) Blade drive: 1.5 kW (2.2 kW Optional VFD)
COOLANT TANK: 6 U.S. Gallons 23 litres
VISE CONTROL: Manual Manual
TABLE HEIGHT: 31” 787 mm
MAXIMUM WORK LOAD: 5,000 lbs 2268 kg
MACHINE WEIGHT: 1,800 lbs 817 kg
DIMENSIONS:80” wide 2037 mm wide
77” long 1955 mm long
55.5” high 1408 mm high
OPTIONS:
• Mechanical overhead bundling clamp
• 3 hp VFD
• Outfeed material stop
• Blade breakage switch
• Worklight & 500 va transformer
• Mist Coolant
• Hydraulic Power Pack
• Variable Vise Pressure • Bundling
8.5
CAPACITY:
90º Rectangle: 16” x 18” 90º Rectangle: 406 mm x 457 mm
90º Round: 16” diameter 90º Round: 406 mm diameter
45º Rectangle: 16” x 10” 45º Rectangle: 406 mm x 254 mm
45º Round: 12” diameter 45º Round: 305 mm diameter
60º Rectangle: 16” x 6” 60º Rectangle: 406 mm x 152 mm
60º Round: 8” diameter 60º Round: 203 mm diameter
BLADE:Length: 4724 mm
Width: 1 1/4” Width: 32 mm
Thickness: .042” Thickness: 1.1 mm
BLADE SPEED:75-350 SFM 22-107 m/min
BLADE GUIDES: Carbide Carbide
BLADE WHEEL DIAMETER:19” 483 mm
DRIVE: Blade drive: 5 hp Blade drive: 3.7 kW
COOLANT TANK: 6 U.S. Gallons 23 litres
VISE CONTROL: Manual Manual
TABLE HEIGHT: 31” 787 mm
MAXIMUM WORK LOAD: 5,000 lbs 2268 kg
MACHINE WEIGHT: 2,000 lbs 907 kg
DIMENSIONS:95” wide 2410 mm wide
77” long 1955 mm long
63” high 1603 mm high
OPTIONS:
• 3 hp VFD
• Outfeed material stop
• Blade breakage switch
• Worklight
• Mist Coolant
• Hydraulic Power Pack
• Variable Vise Pressure
• Bundling
9.1
Hyd-Mech Group Limited warrants parts/components on each new S20/23 bandsaw to be free from failure resulting from defective material and workmanship under proper use and service for a period of two years
by the user.
This warranty, in its entirety, does not cover maintenance items, including but not limited to lubricating grease
abuse, accident, inadequate maintenance, or unauthorized altering.
MOTOR, GEARBOX, PUMP, ELECTRIC COMPONENTS, VALVES, HOSES, FITTINGS, and any other items used in the manufacture of the S20/23, but not originally manufactured by Hyd·Mech are subject to the
Liability or obligation on the part of Hyd·Mech for damages, whether general, special or for negligence and
to repair or replace shall be the limit of its liability under this warranty and the sole and exclusive right and remedy of the user.
THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES, EXPRESSED ORIMPLIED, WRITTEN OR ORAL, INCLUDING WITHOUT LIMITATION ANY IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE.
Group Limited
HYD·MECH GROUP LIMITED1079 Parkinson RoadP.O. BOX 1030Woodstock, OntarioN4S 8P6Phone: (519) 539-6341Fax: (519) 539-5126Toll Free: (877) 276-SAWS (7297)E-mail: [email protected]
SECTION 9 - WARRANTY
Warranty